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Home >> Mercury Truck >> 1997 >> Villager V6-181 3.0L SOHC VIN 1 EFI >> Repair and Diagnosis >> Windows and Glass >> Windows >> Window Glass >> Back Window Glass >> Service and Repair >> Fixed

Fixed

The following tools are recommended:
- Rotunda Interior Auto Glass Out-Out Knife Kit 164-R2450 or equivalent.
- Razor Blade Knife.
- Shop Towels.
- Installation Kit E0AZ-19562-A.
- Alcohol free glass cleaner in a spray bottle.

REMOVAL
1. Disconnect the battery ground cable.
2. Remove the liftgate door trim panel.
3. Remove the liftgate glass trim.
4. Remove the back window glass wiper pivot arm and blade.
5. Disconnect the two heated back glass electrical connectors.
6. Lubricate the urethane sealant to be cut with water to aid the Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent when cutting the urethane sealant.







7. Use Rotunda Interior Auto Glass Cut-Out Knife Kit 164-R2450 or equivalent to cut through the urethane adhesive.

WARNING: TO PREVENT SPLINTERS OF GLASS FROM ENTERING EYES OR CUTTING HANDS, WEAR HEAVY SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM THE VEHICLE.

8. Insert the inflatable pump bag at the top of the back window glass and gently push the back window glass outward 12 mm (1/2 inch) from the inside of the vehicle to ensure the urethane sealant seal is broken. Use a razor blade knife to cut any urethane sealant that may be holding down the back window glass.
9. Remove the back window glass from the liftgate.







10. Trim the remaining old urethane on the pinch weld to within 1.0-2.0 mm (0.04-0.06 inch) thickness using a suitable tool. When completed, the old urethane surface should be smooth and free of cuts and contamination.
11. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material which may cause glass damage. Service the pinch weld sheet metal as necessary.
12. Using the supplied wool applicator, apply Urethane Metal Primer (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld flange. Allow 10 minutes drying time for the primer.

INSTALLATION







1. Scrape any remaining urethane adhesive from the original back window glass if it is being reinstalled.
2. Clean the perimeter of the back window glass with an alcohol free glass cleaner. Dry set the back window glass into the opening and use a suitable tape on all four sides to mark the proper position of the back window glass; remove the back window glass.







3. Apply Urethane Glass Prep (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C in a 25 mm (1 inch) wide application around the entire outer edge of the inside of the back window glass and wipe off immediately. Repeat the application and immediately wipe off glass.

WARNING: IF PRIMER GETS ON YOUR HANDS, REMOVE IT IMMEDIATELY.

NOTE: Wipe off the Urethane Glass Prep (part of EOAZ-19562-A), or equivalent meeting Ford specification WSB-M2G234-C, immediately after application because it flash dries. The Urethane Glass Prep must be applied twice.







4. Apply Urethane Glass Primer (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G314-B, in a 25 mm (1 inch) wide application around the entire outer edge of the inside of the back window glass. Allow 3 to 5 minutes for the primer to dry.







5. Install Open Cell Vinyl Foam Tape C6AZ-19627-A or equivalent meeting Ford specification ESB-M3G77-A to the pinch weld area. Start the foam dam at the center of the bottom pinch weld and lay it around the entire pinch weld 8 mm (0.310 inch) from the inside edge.







6. Cut the nozzle of the urethane sealant canister so that it lays a bead of sealant 16 mm (0.625 inch) high and 8 mm (0.310 inch) wide.







7. Lay a uniform bead of Urethane Sealant (part of EOAZ- 19562-A) or equivalent meeting Ford specification WSB-M2G316-B along the entire liftgate pinch weld area 16 mm (0.625 inch) in height and 8 mm (0.310 inch) wide. Ensure that the bead of urethane sealant is smooth and even. If necessary, reshape the bead with a suitable tool.







8. Install the back window glass.

CAUTION:
- Open the windows to prevent the glass from being pushed out by air pressure if a door is closed.
- After replacing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing time at temperatures above 13°C (55°F) with relative humidity above 50%, is 12-24 hours (decreasing cure at higher temperatures and lower humidities). Refer to the detailed instructions provided by the manufacturer in the kit. Inadequate curing of the urethane may adversely affect the strength of the urethane sealant bond.

NOTE: Use masking tape to hold the back window glass in place until the urethane adhesive cures.

9. After the urethane has cured run water over the back window glass to check for leaks. Apply urethane to any leaking areas and repeat water check.

CAUTION: Use only Urethane Sealant (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G316-B to service water and air leaks in the urethane sealant.

10. Connect the two heated back glass electrical connectors.
11. Install the back window glass wiper pivot arm and blade. Adjust as necessary.
12. Install the liftgate glass trim.
13. Install the liftgate door trim panel.
14. Connect the battery ground cable.
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